Metal-containing transaction card and method of making the same

ABSTRACT

Metal-containing transaction cards, useful for the purchase of goods and/or services are disclosed. The metal-containing transaction cards may be standard-sized (i.e., about 3⅜ inches by about 2 14 inches) or any other size yet still usable as a transaction card. Moreover, the metal-containing transaction card may include a pocket having characters embossed therein. Further, the metal-containing transaction card may include a fill panel disposed within the pocket. The metal may be titanium or stainless steel.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of, and claims priority to,U.S. patent application Ser. No. 10/749,006, filed Dec. 30, 2003 andentitled “Metal Transaction Card and Method of Making the Same.” The'006 application claims the benefit of U.S. Provisional PatentApplication Ser. No. 60/437,938, filed on Jan. 3, 2003 and entitled“Titanium-Containing Transaction Card and Method of Making the Same,”all of which are hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

Metal-containing transaction cards useful for the purchase of goodsand/or services and methods of making the same are provided. Themetal-containing transaction cards may be credit cards, debit cards,check cards, stored-value cards, or any other transaction card. Eachcard may be standard-sized (i.e., about 3⅜ inches by about 2¼ inches) orany other size yet still usable as a transaction card. Moreover, themetal-containing transaction cards may have a magnetic stripe, anembedded microchip, a signature panel, a holographic image, or any otherfeature typically contained on or within a transaction card. Thetransaction cards have at least one layer of metal.

The proliferation of transaction cards, which allow the cardholder topay with credit rather than cash, started in the United States in theearly 1950s. Initial transaction cards were typically restricted toselect restaurants and hotels and were often limited to an exclusiveclass of individuals. Since the introduction of plastic credit cards,the use of transaction cards have rapidly proliferated from the UnitedStates, to Europe, and then to the rest of the world. Transaction cardsare not only information carriers, but also typically allow a consumerto pay for goods and services without the need to constantly possesscash, or if a consumer needs cash, transaction cards allow access tofunds through an automatic teller machine (ATM). Transaction cards alsoreduce the exposure to the risk of cash loss through theft and reducethe need for currency exchanges when traveling to various foreigncountries. Due to the advantages of transaction cards, hundreds ofmillions of cards are now produced and issued annually, therebyresulting in a need for companies to differentiate their cards fromcompetitor's cards.

Initially, the transaction cards often included the issuer's name, thecardholder's name, the card number, and the expiration date embossedonto the card. The cards also usually included a signature field on theback of the card for the cardholder to provide a signature to protectagainst forgery and tampering. Thus, the cards served as devices toprovide data to merchants and the security associated with the card wasthe comparison of the cardholder's signature on the card to thecardholder's signature on a receipt along with the embossed cardholder'sname on the card.

Due to the popularity of transaction cards, numerous companies, banks,airlines, trade groups, sporting teams, clubs and other organizationshave developed their own transaction cards. As such, many companiescontinually attempt to differentiate their transaction cards andincrease market share not only by offering more attractive financingrates and low initiation fees, but also by offering unique,aesthetically pleasing features on the transaction cards. As such, manytransaction cards include not only demographic and account information,but the transaction cards also include graphic images, designs,photographs and security features. A recent security feature is theincorporation of a diffraction grating, or holographic image, into thetransaction card which appears to be three-dimensional. Holographicimages restrict the ability to fraudulently copy or reproducetransaction cards because of the need for extremely complex systems andapparatus for producing holograms.

Administrative and security issues, such as charges, credits, merchantsettlement, fraud, reimbursements, etc., have increased due to theincreasing use of transaction cards. Thus, the transaction card industrystarted to develop more sophisticated transaction cards which allowedthe electronic reading, transmission, and authorization of transactioncard data for a variety of industries. For example, magnetic stripecards, optical cards, smart cards, calling cards, and supersmart cardshave been developed to meet the market demand for expanded features,functionality, and security. In addition to the visual data, theincorporation of a magnetic stripe on the back of a transaction cardallows digitized data to be stored in machine readable form. As such,magnetic stripe readers are used in conjunction with magnetic stripecards to communicate purchase data received from a cash register deviceon-line to a host computer along with the transmission of data stored inthe magnetic stripe, such as account information and expiration date.

Due to the susceptibility of the magnetic stripe to tampering, the lackof confidentiality of the information within the magnetic stripe and theproblems associated with the transmission of data to a host computer,integrated circuits were developed which could be incorporated intotransaction cards. These integrated circuit (IC) cards, known as smartcards, proved to be very reliable in a variety of industries due totheir advanced security and flexibility for future applications.However, even integrated circuit cards are susceptible tocounterfeiting.

As magnetic stripe cards and smart cards developed, the market demandedinternational standards for the cards. The card's physical dimensions,features and embossing area were standardized under the InternationalStandards Organization (“ISO”), ISO 7810 and ISO 7811. The issuer'sidentification, the location of particular compounds, codingrequirements, and recording techniques were standardized in ISO 7812 andISO 7813, while chip card standards were established in ISO 7813. Forexample, ISO 7811 defines the standards for the magnetic stripe which isa 0.5 inch stripe located either in the front or rear surface of thecard and which is divided into three longitudinally parallel tracks. Thefirst and second tracks hold read-only information with room for 79alphanumeric characters and 40 numeric characters, respectively. Thethird track is reserved for financial transactions and includesenciphered versions of the user's personal identification number,country code, currency units, amount authorized per cycle, subsidiaryaccounts, and restrictions.

More information regarding the features and specifications oftransaction cards can be found in, for example, Smart Cards by Jose LuisZoreda and Jose Manuel Oton, 1994; Smart Card Handbook by W. Rankl andW. Effing, 1997, and the various ISO standards for transaction cardsavailable from ANSI (American National Standards Institute), 11 West42nd Street, New York, N.Y. 10036.

The incorporation of machine-readable components onto transactions cardsencouraged the proliferation of devices to simplify transactions byautomatically reading from and/or writing onto transaction cards. Suchdevices include, for example, bar code scanners, magnetic stripereaders, point of sale terminals (POS), automated teller machines (ATM)and card-key devices. With respect to ATMs, the total number of ATMdevices shipped in 1999 was 179,274 (based on Nilson Reports data)including the ATMs shipped by the top ATM manufacturers, namely NCR(138-18 231st Street, Laurelton, N.Y. 11413), Diebold (5995 Mayfair,North Canton, Ohio 44720-8077), Fujitsu (11085 N. Torrey Pines Road, LaJolla, Calif. 92037), Omron (Japan), OKI (Japan) and Triton.

Typical transaction cards are made from thermoplastic materials, such aspolyvinyl chloride (PVC) and polyethylene terephthalate (PET). However,these transaction cards are susceptible to being damaged or destroyed ifexposed to damaging environments. For example, transaction cards may bedamaged if left exposed to the elements for an extended period of time.Moisture and/or sunlight may break down the chemical bonds within thepolymers of typical transaction cards, such that transaction cards leftexposed to moisture and sunlight may become warped, cracked andunusable. In addition, thermoplastic transaction cards may be easilybent or may be broken or cut, thereby damaging the transaction card andrendering it unusable.

A need, therefore, exists for a transaction card that has both strengthand durability. Moreover, a need exists for a transaction card thatwithstands exposure to the elements, such as moisture or sunlight. Aneed further exists for a transaction card that may incorporate thefeatures noted above, such as holograms, signature panels, magneticstripes, microchips, and the like, such that is has both strength anddurability. In addition, a need exists for a transaction card thatovercomes the problems noted above.

SUMMARY OF THE INVENTION

The present invention relates to a metal-containing transaction card anda method of making the same. The metal-containing transaction card maybe standard-sized (i.e., about 3⅜ inches by about 2¼ inches) or anyother size yet still usable as a transaction card. Moreover, thetransaction card may have a magnetic stripe, an embedded microchip, asignature panel, a holographic image, or any other feature typicallycontained on or within the transaction card. The transaction card of thepresent invention has at least one layer of metal. Preferably, thetransaction card of the present invention has at least one layer oftitanium or stainless steel.

A transaction card and a method of making the same are provided wherebythe transaction card has at least one layer of metal. The at least onelayer of metal provides durability and strength to the transaction card.The one layer of metal may be any metal able to be utilized as atransaction card or incorporated into or within a transaction card.Preferably, the at least one layer of metal is titanium, stainless steelor aluminum.

Further, a transaction card having at least one layer of metal isprovided whereby the transaction card is of a standard size, i.e.,compliant with the International Standards Organization (ISO) fortransaction cards.

In addition, a transaction card having at least one layer of metal mayfurther have other layers that include one or more polymeric materialsor other metal material, such as aluminum and the like.

Still further, a metal-containing transaction card is provided havingfeatures typically contained on or in transaction cards, such asmagnetic stripes, embedded microchips, signature panels, holographicimages, and the like. Moreover, the metal-containing transaction cardmay be printed with indicia, such as via screen-printing or alaser-etching process to uniquely identify the transaction card and/orthe issuer of the transaction card or any other information.

Still further, a method of making a single transaction is providedcomprising embossing the single transaction card within a pocket to formembossed characters on a first surface of the single transaction cardand filling the pocket with a fill panel to provide a substantiallyflush surface on a second surface of the single transaction card,wherein an entire surface of the single transaction card is comprised ofa continuous metal layer and, wherein a third surface of the fill panelis in uniform, direct contact with an interior of the pocket.

Further still, a method of making a single transaction is providedcomprising cutting a pocket within the single transaction card andapplying a recordable medium on the single transaction card for storinginformation relating to a transaction account, wherein the singletransaction card is comprised of a continuous metal layer, wherein thesingle transaction card is configured to be embossed within the pocketto provide embossed characters on a first surface of the singletransaction card, wherein the single transaction card is configured tohave a fill panel disposed within the pocket to provide a substantiallyflush surface on a second surface of the single transaction card,wherein a third surface of the fill panel is configured to be inuniform, direct contact with an interior of the pocket.

Additional features and advantages of the present invention aredescribed in, and will be apparent from, the detailed description of thepresently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a plan view of a front face of a metal-containingtransaction card.

FIG. 1B illustrates a plan view of a back face of a metal-containingtransaction card.

FIG. 2A illustrates a cross-sectional view of a metal-containingtransaction card along line II-II of FIG. 1B.

FIG. 2B illustrates a cross-sectional view of an alternate embodiment ofa transaction card along line II-II of FIG. 1B.

FIG. 2C illustrates a cross-sectional view of another alternateembodiment of a transaction card along line II-II of FIG. 1B.

FIG. 2D illustrates a cross-sectional view of a still further alternateembodiment of a transaction card along line II-II of FIG. 1B.

FIG. 2E illustrates a cross-sectional view of another alternateembodiment of a transaction card along line II-II of FIG. 1B.

FIG. 3 illustrates a flow chart showing a method of makingmetal-containing transaction cards.

FIG. 4 illustrates a flow chart showing an alternate method of makingtitanium transaction cards.

FIG. 5 illustrates another flow chart showing an alternate methods oftitanium transaction cards.

FIG. 6 illustrates an alternate flow chart showing a still furtheralternate method of making titanium transaction cards.

FIG. 7 illustrates a plan view of a titanium card made during themethods of making the titanium transaction cards.

FIG. 8 illustrates a plan view of a fill panel made during the methodsof making the titanium transaction cards.

FIG. 9 illustrates a plan view of an embossed titanium card made duringthe methods of making the titanium transaction cards.

FIG. 10 illustrates a plan view of a titanium card having a fill paneldisposed within a pocket.

FIG. 11 illustrates a cross-sectional view of the titanium card havingthe fill panel disposed within the pocket.

DETAILED DESCRIPTION

Metal-containing transaction cards and methods of making the same areprovided. The transaction cards may be standard-sized (i.e., about 3⅜inches by about 2¼ inches) or any other size yet still usable as atransaction card. Moreover, the transaction card may have a magneticstripe, an embedded microchip, a signature panel, a holographic image,or any other feature typically contained on or within a transactioncard. The transaction cards have at least one layer of metal, preferablytitanium or stainless steel.

Referring now to the drawings, wherein like numerals refer to likeparts, FIG. 1 illustrates a plan view of a metal-containing transactioncard 1 having a front face 10. The transaction card 1 is composed of atleast one layer of metal that has been flattened into a card shape.Typically metal can be rolled into a sheet. The sheet can then be cut toform individual transaction cards.

Any metal may be utilized as the layer or layers of the transactioncards described herein. Specifically, the metals may include titanium,stainless steel, or aluminum, although any other metal is contemplatedby the present invention.

On the front face 10 of the transaction card 1 may be indicia, such asimages, graphics, words, or other symbols, that may be printed on thefront face 10 using conventional printing techniques. Alternatively, theindicia may be laser-etched. A typical laser-etching device forlaser-etching metal, such as titanium or stainless steel, is done by alaser from Virtek Vision International, Inc. Lasers can provide markingof metals such as titanium, stainless steel or aluminum of depths of upto 0.100 inches and as low as about 0.003 inches. A pattern may be lasermarked onto the front face 10 (or the rear face 20, as described belowand illustrated by FIG. 1B).

In addition, the laser-etching of the metal layer, typically titanium,may provide the transaction card 1 with a plurality of colors on one orboth of the faces of the card 1. Specifically, the energy utilized tolaser-etch the metal may allow the metal to recrystallize in such a wayas to be viewable by an individual as being of a specific color orcolors.

In an alternative embodiment, one or both faces of the transaction card1 may be anodized using conventional anodizing methods, therebyproviding a surface on one or both faces of the transaction card 1 thatmay sealed with an oxide layer thereby protecting the metal and allowingthe surface to be receptive to printing inks or coatings. In addition,the anodizing process may provide a color to one or both faces of thetransaction card 1. For example, the anodizing process may comprisetreatment of the surface of the metal with an ionic solution under anelectrical current, which can provide one or both faces of thetransaction card 1 with a color depending on the voltage of theelectricity that is used to anodize the one or both faces of thetransaction card 1.

A coating may be applied to one or both faces of the transaction card 1.Preferably, the coating may be a silane compound thereby providing themetal in the transaction card 1 resistance to scratches, damage,fingerprints, and the like. In addition, a dye or ink may beincorporated into the silane coating thereby providing the transactioncard 1 with a particular color. Typically, the silane and the dye areprovided across one or both surfaces of the transaction card 1.Preferably, the silane coating may be incorporated with a black dyewhereby one or both faces of the transaction card 1 will have a blackappearance. Of course, any other colored coating may be applied to thesurface of one or both faces of the transaction card 1 after the surfaceof one or both faces of the transaction card 1 are anodized, such asacrylic or polyethylene terephthalate. In addition, the surface coatingmay be comprised of a thermoset polymeric material, applied to one orboth faces of the transaction card. The thermoset material may beapplied to the transaction card 1 by coating one or both faces of thetransaction card 1 with dry powder of the thermoset material, and bakingthe thermoset material to melt the same and set the material on thesurface of the transaction card 1. Of course, the transaction card 1 maybe provided with no colored coating, thereby providing a metal-coloredtransaction card, whereby the natural color of the metal may beviewable.

FIG. 1B illustrates a rear face 20 of the transaction card 1 of thepresent invention. Provided on the rear face 20 may be a magnetic stripe22 that may be applied to the rear face 20 using conventional methods,such as by stamping the magnetic stripe to the transaction card 1.Moreover, a signature panel 24 may be provided as well and may also bestamped to the transaction card 1 or applied via any other conventionalmethod. The signature panel allows the owner of the transaction card toplace his or her signature on the transaction card, thereby providing asecurity feature. In addition, a microchip may be embedded into thetransaction card of the present invention. Of course, any other featuremay be included on the front face 10 or the rear face 20 of thetransaction card 1 as may be apparent to one having ordinary skill inthe art.

FIG. 2A illustrates a cross-sectional side view of the transaction card1 along lines II-II of FIG. 1B. As illustrated, the transaction card 1includes at least a first layer 26 of metal. Of course, the transactioncard 1 may comprise two or more layers of metal that are adheredtogether via heat, pressure, and/or adhesive. Preferably, thetransaction card 1 contains at least one layer of titanium or stainlesssteel. The first layer 26 further includes the magnetic stripe 22 andthe signature panel 24 adhered directly to the first layer 26 of metal.Preferably, the total thickness of the first layer 26 is about 30 mils,although other thicknesses of the first layer 26 are contemplated by thepresent invention.

The layers illustrated in FIGS. 2A-2E are exaggerated in thickness toclearly illustrate the structures of the transaction cards describedherein.

The transaction card 1 may be stamped, embossed or etched to providetexture, images, alphanumeric characters, or the like. As describedabove, the front or rear surfaces of the transaction card 1 may beprinted or laser-etched to provide indicia, such as graphics, images,text, or any other indicia. In addition, the surface of each face of thefirst layer 26 may be anodized and/or coated with a coating to protectthe surfaces of the metal and/or to provide the surfaces with a color.Moreover, an adhesive (not shown) may be provided for adhering themagnetic stripe 22 and the signature panel 24 to the metal of the firstlayer 26. Further, a microchip (not shown) may be embedded into thefirst layer 26 of metal to provide smart card capabilities to thetransaction card made therefrom.

FIG. 2B illustrates an alternate embodiment of the present invention ofa cross-sectional view of the transaction card 1 along line II-II ofFIG. 1B. As illustrated, the transaction card 1 includes a metal layer30, and an optional adhesive layer 32 to adhesively secure the magneticstrip 22 and signature panel 24 to the metal layer 30. The adhesivelayer 32 may be laminated, coated, or otherwise applied to the metallayer 30. Preferably, the total thickness of the transaction card 1including the metal layer 30 and the adhesive layer 32, as illustratedin FIG. 2B, is about 30 mils, although other thicknesses arecontemplated in the present invention. Preferably, the metal layer 30 ismade of titanium or stainless steel.

Alternatively, the transaction card does not include an adhesive layer,as illustrated in FIG. 2A, and the magnetic stripe 22 and/or signaturepanel 24, as well as any other feature, is applied directly to one orboth surfaces of the metal layer 30. Alternatively, the transaction card1 may have an adhesive layer (not shown) provided on the front face 10of the transaction card 1 for adhering inks or other printing to themetal layer 30.

The transaction card of FIG. 2B may be stamped, embossed or etched toprovide texture, images, graphics, alphanumeric characters or the liketo the transaction card. As described above, the front or rear surfacesof the transaction card may be printed or laser-etched to provideindicia, such as graphics, images, text, or any other indicia.

FIG. 2C illustrates an alternate embodiment of the present invention ofa cross-sectional view of a transaction card taken along line II-II ofFIG. 1B. In the embodiment illustrated in FIG. 2C, the transaction card1 comprises a core layer 40 of a substrate, such as a thermoplasticmaterial of, for example, PVC, PET copolymer, or other substrate.Further, the core layer 40 has a layer of metal laminated to one or bothsides of the core layer 40. In FIG. 2C, the core layer 40 has a firstmetal layer 42 laminated or otherwise disposed adjacent to a firstsurface of the core layer 40 and a second metal layer 44 laminated orotherwise disposed adjacent to a second surface of the core layer 40.The core layer 40 may be about 18 mils, while each metal layer 42, 44may be about 6 mils to provide a transaction card that is about 30 milsin total thickness. However, the core layer 40 and metal layers 42, 44may be any thickness. Preferably, the metal layers 42, 44 are titaniumor stainless steel.

Provided on the second metal layer 44 may be an adhesive 46 laminated orotherwise applied thereto for providing adhesion for the magnetic stripe22, signature panel 24, or other feature typically included on atransaction card. Alternatively, an adhesive layer (not shown) isprovided on the first metal layer 42 for providing adhesion to inks forprinting purposes, or for any other reason. Alternatively, there is noadhesive layer between the magnetic stripe 22, signature panel 24, orother feature typically included on the transaction card and the firstand/or second metal layers 42, 44.

In addition, the transaction card of FIG. 2C may be stamped, embossed oretched to provide texture, images, graphics, alphanumeric characters orthe like to the transaction card. As described above, the front or rearsurfaces of the transaction card may be printed or laser-etched toprovide indicia, such as graphics, images, text, or any other indicia.

FIG. 2D illustrates a fourth embodiment of the present invention,whereby the transaction card 1, illustrated in a cross-sectional view inFIG. 2D, comprises a first layer 50 of a substrate, such as athermoplastic material of, for example, PVC or PET copolymer, and asecond layer 52 of metal laminated or otherwise disposed adjacent to thefirst layer 50. The first layer 50 and the second layer 52 may havethicknesses that sum to about 30 mils. For example, the first layer maybe about 18 mils and the second layer (of metal) may be about 12 mils.However, the layers may be any other thicknesses. Preferably, the secondlayer 52 of metal is titanium or stainless steel.

The first layer 50 may further include an adhesive 54 to provideadhesion to the magnetic stripe 22, the signature panel 24, or to anyother feature contained on the transaction card 1. Alternatively, noadhesive layer is present.

FIG. 2E illustrates a fifth embodiment of the present invention, wherebythe transaction card 1, illustrated in a cross-sectional view in FIG.2E, comprises a first layer 60 of a metal substrate, such as aluminum,or other metal substrate, and a second layer 62 of a second metallaminated or otherwise disposed adjacent to the first layer 60.Preferably, the second layer 62 is titanium or stainless steel, althoughother metals are contemplated by the present invention. As with thetransaction cards described above, the first layer 60 may have anadhesive layer 64 laminated or otherwise applied thereto for providingadhesion to the magnetic stripe 22 or the signature panel 24. As withthe other embodiment described above, the adhesive may be provided onthe second layer as well for providing adhesion to inks for printing, orfor other features typically contained on a transaction card.Alternatively, no adhesive layer is present.

FIG. 3 illustrates a method 100 of making a metal-containing transactioncard of the present invention, wherein the metal is titanium.Specifically, the method 100 includes a first step 102 of preparing thetitanium to form into transaction cards. Specifically a sheet oftitanium may be prepared that is about 30 mils thick. Typically, thetitanium metal is rolled and flattened to the required thickness.Preferably, the titanium sheet comprises titanium metal that has littleto no magnetic properties, so that the titanium does not interfere withthe magnetic stripe and/or microchip that may be embedded within thetransaction card.

In an anodizing step 104, the titanium sheet is anodized using aconventional anodizing process. Specifically, the titanium may bedisposed in a bath having ions and an electrical current therein toanodize one or both of the faces of the sheet of titanium. As notedabove, anodizing the sheet of titanium can provide one or both faces ofthe sheet of titanium with a colored surface, depending on the currentthat is supplied during the anodizing process, as is apparent to onehaving ordinary skill in the art. Moreover, anodizing oxidizes thesurface of the titanium, thereby sealing and protecting the titanium.

In a coating step 106, a coating is applied to one or both faces of thesheet of titanium to provide one or both faces of the sheet with a colorand to further protect the titanium. Specifically, the coating may be asilane coating having a dye contained therein, wherein the silane iscoated as a layer on one or both faces of the transaction card. Thesilane coating may be applied in a waterless solvent or a water-basedsystem.

In addition, other materials that may be coated to one or both faces ofthe transaction card are polyethylene terephthalate and acrylic,although any other coating may be utilized to provide a coating toprotect the titanium and, optionally, to provide a color to the one orboth faces of the transaction card. For example, the coating may be madefrom a thermoset material that may be sprayed onto the one or both facesof the transaction card in powder form. The transaction card may then bebaked, and the powder may melt to the surface of the transaction card.

Step 108 illustrates a cutting step whereby the sheet of titanium, whichmay have been anodized and/or coated as described above, may be cut intoindividual transaction card shapes. Common methods of cutting titaniuminclude, but are not limited to, water jet cutting, die cutting, lasercutting or plasma cutting. The goal in cutting the titanium is to easilyand efficiently cut the titanium sheet into transaction card shapeswhile avoiding sharp edges.

After cutting the titanium sheet via step 108, the individualtransaction cards may be laser-engraved via a laser-engraving step 110.The laser engraving may be done via commonly known laser engravingtechniques to provide a pattern in one or both faces of the transactioncard. Moreover, the laser engraving may cut away a coating that may bedisposed on the one or both faces of the transaction card, therebyproviding a visible pattern. For example, if a black coating is appliedto the titanium sheet via step 106, the laser beam may etch a pattern inthe black coating to give a pattern that is not black, but may be metalcolored, or colored in any other way. In addition, the laser beam maymelt the surface of one or both faces of the transaction card, which maycause the titanium to recrystallize when cooled. The recrystallizationmay produce a variety of colors in the surface of one or both faces ofthe transaction card. Preferably, the laser engraving step 110 may beaccomplished via a laser, such as, for example, a YAG laser having awavelength of about 1064 nanometers. Of course, any other laser may beutilized that provides a pattern, a texture or a color to the titaniumas may be apparent to one having ordinary skill in the art.

After laser engraving the transaction card, a magnetic stripe andsignature panel of the transaction card may be applied to thetransaction card via step 112. Typically, the magnetic stripe and thesignature panel are stamped using techniques common in the art of makingtransaction cards. Specifically, the magnetic stripe and signature panelare applied to one or both of the faces of the transaction card with theuse of an adhesive that may be applied on one or both faces of thetransaction card. Preferably, the adhesive may be screen-printed to oneor both faces of the transaction card, although any other method ofapplying the adhesive is contemplated by the present invention. Mostmaterials require the use of an adhesive to stick to one or both facesof the transaction card. However, certain coatings may allow themagnetic stripe and the signature panel to be applied without the use ofadhesives. For example, a coating of thermoplastic, such as a flat blackvinyl thermoplastic, may be coated onto the card and may allow themagnetic stripe and the signature panel to be applied to the transactioncard without adhesive. The stamping process may melt the thermoplasticmaterial, thereby allowing the thermoplastic material to adhere themagnetic stripe and/or the signature panel when cooled and solidified.

After the magnetic stripe and the signature panel have been applied tothe transaction card, the transaction card may be milled via step 114 toprovide a space to apply an embedded microchip for a smart card. Themilling process may be done in a similar manner to conventional plastictransaction cards, but may be accomplished with a boron nitride, boroncarbide tipped machine or other machine able to mill titanium. Inaddition, the transaction card may be milled via a cryo-milling process,in which the mill head is cooled with a stream of liquid nitrogen toensure that the transaction card and/or the mill head does not overheat.Typically, the transaction card may have an area about 20 to about 25mils deep milled from the transaction card to provide a space for themicrochip. The microchip may be applied to the milled area of thetransaction card, and may stay within the milled area due to an adhesivethat may be provided.

After milling the transaction card to embed the microchip therein, thetransaction card may be embossed via an embossing step 116.Specifically, the embossing may be done by subjecting the transactioncard to a high pressure die that may punch a character or a plurality ofcharacters into the surface of the transaction card. The embossing maybe done to provide information on the surface of the transaction cardthat may be readable by an individual or a machine. Specifically, anaccount number or other unique identifier is typically embossed on atransaction card. Preferably, the embossing step 116 may be accomplishedwith an addressograph machine. Of course, other methods of embossing thetransaction card are contemplated, and the invention should not belimited as herein described.

Finally, the transaction card may be encoded via step 118 via anyencoding steps commonly used to encode the transaction cards.Specifically, either or both of the recordable media, such as themagnetic stripe and/or the microchip, may be encoded to provide thetransaction card having information contained thereon within therecordable media. The recordable media may be read via a magnetic stripereader or a microchip reader, as may be apparent to one having ordinaryskill in the art.

FIG. 4 illustrates an alternate method 200 of making transaction cardscomprising titanium. The method 200 comprises a first step 202 ofpreparing the titanium by rolling and flattening the titanium into asheet to form into transaction cards. The first step 202 may besubstantially similar to the first step 102 described above with respectto FIG. 3.

After the titanium sheet is prepared via step 202, the titanium sheetmay be cut in a cutting step 204, whereby the sheet of titanium may becut into individual transaction card shapes. For example, the titaniumsheet may be cut via the methods described above with respect to step108 of FIG. 3.

Once the individual transaction cards have been cut from the titaniumsheet, each individual transaction card may be tumbled and cleaned tosmooth any sharp edges via a tumbling and cleaning step 206. It isimportant to ensure that all of the edges are smooth.

After the transaction cards have been smoothed and cleaned, eachtransaction card may be anodized and primed via an anodizing step 208.The anodizing step may be substantially similar to the anodizing step104 as described above with reference to FIG. 3.

After being anodized and primed, each transaction card may be coated andoven cured via a coating step 210. The coating step 210 may besubstantially similar to the coating step 106 as described above withreference to FIG. 3. Each side of each transaction card may be coatedand oven-cured separately in a multi-step process.

After each side of each transaction card is coated and oven-cured, eachtransaction card may be laser engraved via laser engraving step 212,which may be substantially similar to the laser-engraving step 110, asdescribed above with reference to FIG. 3.

Once each transaction card is laser engraved, a primer may be applied toone or both of the surfaces by screen printing the primer via a primingstep 214. The primer may be applied across the entire surface of eachtransaction card, or may be applied precisely where a magnetic stripeand/or signature panels are desired.

After each transaction card is primed, the magnetic stripe and/orsignature panels may be applied via step 216. The magnetic stripe and/orsignature panel may be applied in a substantially similar way asdescribed in step 112, described above with respect to FIG. 3.

After the magnetic stripe and/or signature panels have been applied,each of the surfaces of each transaction card may be laser scored viastep 218 to provide graphics, text and numerals to either or both of thesurfaces of each transaction card.

Once each transaction card has been laser scored to provide graphics,text or numerals, a microchip may be disposed within the transactioncard via step 220. For example, the transaction card may be milled toprovide a space in the transaction card for an embedded microchip. Thedisposing of the microchip into the transaction card may be done in asubstantially similar manner as step 114, described above with referenceto FIG. 3.

Each transaction card may then be embossed via an embossing step 222,which may be substantially similar to the embossing step 118, asdescribed above with reference to FIG. 3. Further, the magnetic stripeand/or microchip may be encoded. The transaction cards may then beshipped to customers.

Finally, each transaction card's recordable media, such as the magneticstripe and/or the embedded microchip, may be encoded via an encodingstep 224.

In an alternate method of making titanium transaction cards 300illustrated in FIG. 5, sheets of titanium are prepared via step 302. Thetitanium sheets may be prepared as described above in steps 102, 104with respect to FIGS. 3, 4. Specifically sheets of titanium may beprepared that are about 30 mils thick. In addition, sheets of titaniummay be prepared that are about 15 mils thick, that will be cut into fillpanels, as described below. Typically, the titanium metal is rolled andflattened to the required thickness. Preferably, the titanium sheetscomprise titanium metal that has little to no magnetic properties, sothat the titanium does not interfere with the magnetic stripe and/or amicrochip that may be embedded within the transaction card.

The 30 mil thick titanium sheets are then cut into individual cards viastep 304. At the same time, the edges of the individual cards may bebeveled to create camfer edges. Preferably, the camfer edges may beprepared on both sides of each individual card on all four edges of eachtitanium card. Alternatively, the camfer edges may be prepared on onlyone side of each titanium card, such as on a front surface of eachtitanium card. In addition, at the same time that the camfer edges areprepared, a pocket may be milled into each individual card. The pocketmay be milled into a backside of each transaction card at the samelocation on the transaction card that is embossed to provide characterson the front surface of each transaction card.

FIG. 7 illustrates a titanium card 350 prepared by the method describedin FIG. 5. Specifically, the transaction card has a pocket 352 that ismilled into the backside 354 of a titanium card that eventually will bemanufactured into a transaction card, having typical transaction cardfunctionality.

Referring now to FIG. 5, the 15 mil thick titanium sheets may then becut into individual fill panels via step 306. FIG. 8 illustrates a fillpanel 360 made by the process described herein with respect to FIG. 5.The fill panel will fit within the pocket 352, as shown in FIG. 7, whenplaced therein with a suitable adhesive. When the fill panel is disposedwithin the pocket 352 with a suitable adhesive, the fill panel forms asmooth surface on the backside of the titanium card 354, as illustratedby FIG. 10.

Both the cards and the fill panels may then be brushed via step 308 toprovide a nice finish on each transaction card made. Typically, thebrushing is done via known titanium brushing techniques to providetitanium surfaces having a grain running in the same direction. Thebrushing may also create titanium surfaces on each transaction cardhaving any other type of pattern.

Both sides of each titanium card may be coated via step 310 by physicalvapor deposition (“PVD”) of a coating that may be utilized to bothprotect the titanium surfaces and provide a distinctive appearance.Preferably, the coating may be titanium carbonitride, which, when vapordeposited on the surfaces of each titanium card, provides an even andsubstantially black coating to each surface of each titanium card. Onesurface of each fill panel may also be coated by physical vapordeposition. Specifically, the surface of the fill panel that is disposedon the outside of the transaction card when the fill panel is adhesivelydisposed within the pocket 352 should be coated by physical vapordeposition. Other coating techniques may also be utilized to provide thecoating on the titanium card as apparent to one having skill in the art.

Graphics may then be laser etched into the titanium card via step 312.Specifically, the laser etching may etch both the coating and thetitanium to provide the graphics, as described above.

Primer may be applied to the backside of each titanium card via step 314to allow the magnetic stripe and the signature panel to be hot stampedthereon, via step 316. A primer material that may be utilized is knownas “passport transfer material,” and may be utilized to allow themagnetic stripe and the signature panel to adhere to the titanium and/orthe coating applied by physical vapor deposition, as described above.The signature panel and the magnetic stripe may be substantially similarto or identical to typical magnetic stripes and signature panelstypically utilized in transaction cards.

Each titanium card may then be embossed via step 318. The embossing ofthe characters may be applied on the surface of the titanium within thepocket, as illustrated in FIG. 9 by a suitable embossing machine, suchas an addressograph machine, wherein each embossed character 362 isrepresented by an “X”. The embossing is done within the pocket 352 sothat the embossing may be done in titanium that is thinner than thetotal thickness of the transaction card. It has been found thatembossing the characters 362 in thinner titanium is easier, and providesclearer and more visible characters, without distortion or warping ofthe characters or of the transaction card.

The recordable media that may be contained within each titanium card maythen be recorded via step 320. For example, magnetic stripes aretypically disposed on a surface of a transaction card. The magneticstripe disposed on the surface of each titanium card may be encoded viastep 320. In addition, if other recordable media are present, such as anembedded microchip, it may be encoded via step 320.

Each embossed character displayed on the front surface of eachtransaction card may then be “tipped” or sanded or abraded to remove thecoating applied by the physical vapor deposition. This allows eachcharacter to obtain a metallic hue that is easily and clearly visiblewhen contrasted with the substantially black coating on the remainder ofthe transaction card.

The fill panel 360 may then be adhered within the pocket 352 via step324. A suitable adhesive may be utilized that adheres the titaniumsurface of the fill panel 360 with the titanium surface within thepocket 352 or the coating that may be on the surface of within thepocket 352 by physical vapor deposition. A suitable adhesive is known as“die mount adhesive”, which is a heat activated film. FIG. 10illustrates a titanium card with the fill panel 360 disposed within thepocket. FIG. 11 illustrates a cross-sectional view of the transactioncard of FIG. 10 illustrating an adhesive 364 that may adhere the fillpanel 360 within the pocket. An embossed character 362 is furtherillustrated in FIG. 11 protruding from the front surface of thetransaction card. Utilizing the fill panel 360 provides embossedcharacters that protrude from the front surface of the transaction cardwithout being visible from the backside of the transaction card.

FIG. 6 illustrates an alternate method 400 of making titaniumtransaction cards. The method 400 is similar to the method 300,described above with respect to FIG. 5. However, the transaction cardmade by the method 400 may have a chamfer edge that is bare. In otherwords, the titanium transaction card may have a coating thereon, such asapplied via physical vapor deposition. However, the chamfer edges mayhave a metallic hue because the coating may be removed at the edges tocreate a transaction card having a metallic “frame” around eachtransaction card.

A first step 402 of preparing the titanium sheets may be similar, if notidentical, to the step of preparing the sheets as described in FIG. 5,above. Step 404 entails applying the coating to the titanium sheets sothat the entire titanium sheets are coated prior to cutting the sheetsinto individual cards and fill panels, which is done via step 406. Whencutting each titanium sheet into individual titanium cards via step 406,each edge of each transaction card may be beveled to create the chamferedges without the coating disposed thereon. The pocket, as illustratedin FIG. 7 is also milled during step 406.

The fill panels are cut from the 15 mil thick titanium sheets via step408. When coating the titanium sheets utilized as the fill panels, onlyone surface of the sheet need be coated via vapor deposition. However,having both surfaces coated by physical vapor deposition does not changethe method described herein.

Each chamfer edge may be brushed and cleaned via step 410 to providesmooth edges having metallic grain running in the same direction.Alternatively, the edges may be brushed to provide patterns in thetitanium on the edges of the transaction cards.

The titanium cards may then be etched to provide graphics via step 412.Primer may be applied for the magnetic stripe and signature panel foreach transaction card via step 414. The magnetic stripe and signaturepanel may be applied via step 416. The card may be embossed via step418. The recordable media may be encoded via step 420. Each embossedcharacter may be “tipped” via step 422. And the fill panel may beadhered within the pocket via step 424. Each step 412-424 may besubstantially similar to or identical to the steps 312-324, as describedabove with respect to FIG. 5.

It should be noted that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages. It is, therefore, intendedthat such changes and modifications be covered by the appended claims.

1. A method of making a single transaction card comprising: embossingthe single transaction card within a pocket and from the bottom of thepocket to form embossed characters on a top surface of the singletransaction card, wherein the top surface comprises a first surface; andfilling the pocket with a fill panel to provide a substantially flushsurface on a second surface of the single transaction card, wherein anentire surface of the single transaction card is comprised of acontinuous metal layer and, wherein a third surface of the fill panel isin uniform, direct contact with an interior of the pocket.
 2. The methodof claim 1, wherein the continuous metal layer comprises at least one oftitanium, aluminum or stainless steel.
 3. The method of claim 1, whereinthe continuous metal layer is anodized to provide an oxide layer on atleast one of the first surface or the second surface.
 4. The method ofclaim 1, wherein the continuous metal layer is covered with a coating.5. The method of claim 4, wherein the coating comprises a materialselected from the group consisting of silane, polyethyleneterephthalate, acrylic, titanium carbonitride, and a thermoset polymericmaterial.
 6. The method of claim 4, wherein the coating comprises a dyefor providing a color to the single transaction card.
 7. The method ofclaim 1, wherein a signature panel is applied to the second surface ofthe continuous metal layer.
 8. The method of claim 7, wherein anadhesive is applied to the second surface of the continuous metal layerprior to the signature panel being applied to the second surface of thecontinuous metal layer, and the signature panel is applied to theadhesive.
 9. The method of claim 1, wherein the fill panel comprises atleast one of a thermoplastic polymer, titanium, aluminum or stainlesssteel.
 10. The method of claim 1, wherein the fill panel comprises athermoplastic polymer selected from the group consisting of polyvinylchloride and polyethylene terephthalate copolymer.
 11. The method ofclaim 1, wherein the single transaction card further comprises arecordable medium.
 12. The method of claim 1, wherein the singletransaction card further comprises laser etching.